Microwaveable packaged food product

ABSTRACT

A package containing nuts and suitable for microwave heating is described herein. The package is configured to heat the nuts and provide an aroma reminiscent of traditional, freshly-roasted nuts. The freshly-roasted nut attributes include an aroma, temperature, texture and taste, which are reproduced with the microwave package. The package preferably, though not necessarily, incorporates one or more susceptors in order to provide additional heating, such as conductive heating, to the nuts. The package also preferably includes a sufficient headspace to allow for the aromas to develop.

FIELD

This disclosure relates generally to microwaveable food products, andmore specifically to a packaged food product for retail sale in whichthe packaging enables enhancement or optimization of organolepticproperties of the food product contained therein during microwaveheating.

BACKGROUND

One of the challenges associated with microwave heating of certain foodproducts is the need to avoid generation of undesired aroma components,e.g., those that may result from overheating or scorching, whileachieving desired aroma notes and while warming the product generallyuniformly.

Some food products have a well-defined configuration, e.g., solid,one-piece farinaceous food products, which can help to provideconsistency and repeatability in response to exposure to microwaveenergy for a particular period of time at a particular power setting ina particular type of oven. A package of mixed, shelled nuts, on theother hand, can be subject to intra-package reconfiguration before,during and after heating, and accordingly different packages containingthe same mass of shelled nuts can react differently to the samemicrowave energy exposure. One particular problem that can occur wherenuts or nut pieces of various varieties and sizes are included in asingle package is that small pieces may be susceptible to overheating,particularly if they are disposed in “hot spots,” e.g., in contact witha susceptor, or at locations where microwave energy is concentrated orof a higher magnitude due to variations in field strength within amicrowave oven cavity.

Another problem is that variations in microwave field strength andconfiguration among various microwave ovens can present problems withrespect to providing a package that will perform satisfactorily in avariety of commonly used, commercially available microwave ovens.

Another problem relates to quantification of desirable aromacharacteristics. Different consumers may perceive the same aromacomponents in different ways. Thus, application of objective standardsin order to provide desirable aroma characteristics while also reducingor eliminating undesirable aroma components can be difficult.

SUMMARY

Described herein is a packaged food product comprising a measuredquantity of a food product contained within a package that optimizes orenhances organoleptic properties of the food product during microwaveheating. The food product may comprise almonds, including, e.g.,Mission, Carmel and Non-Pareil almonds, Brazil nuts, cashews includinge.g. 320 cashews, chestnuts, granola, hazelnuts, macadamia nuts, peanutsincluding e.g. Jumbo Runner peanuts and Virginia Extra Large peanuts,pecans, pistachios, pine nuts, pumpkin seeds, sunflower seeds, walnuts,and/or other food items. The food product may include GMO ingredients,or may be free from GMO ingredients. In some embodiments, the nuts inthe package are shelled nuts, i.e., nuts from which shells have beenremoved. In other embodiments, the nuts in the package may be partly orentirely unshelled, i.e., they may include shells which have not beenremoved, or shells that have been only partially removed. In someembodiments, the nuts may include shells that have been partly opened toexpose the kernels within the shells.

In some embodiments, the food product comprises one or more varieties ofraw or partially-roasted shelled nuts. A modified atmosphere comprising,e.g., nitrogen, carbon dioxide, and/or combinations of these or othergases may be also provided by gas flushing the package, thereby reducingthe volume of oxygen in the package. The package may be configured tocooperate with a microwave oven to heat the shelled nuts and provide anaroma reminiscent of traditional, freshly-roasted nuts, as well asadditional freshly-roasted nut attributes including temperature, textureand taste. The package preferably, though not necessarily, incorporatesone or more susceptors to provide localized enhanced heating, such asconductive heating, to certain components of the food product, while theentire food product is heated as a result of exposure to microwaveenergy. The package also may include a predetermined volume of headspaceto facilitate aroma development.

In some embodiments, the package comprises a pouch formed of a flexiblefilm. The pouch may be hermetically sealed. In some embodiments, thepouch may contain a measured quantity of a food product such as shellednuts, wherein the total weight of the food product is at least 0.75 oz.,and no more than 2 oz. In some embodiments, the food product may consistof about 1.0 oz. to about 1.5 oz., or about 1 oz., of shelled nuts. Inother embodiments, the food product may include a larger quantity ofnuts weighing, e.g., about 6 oz.

Where susceptors are employed, they are preferably disposed within theflexible film pouch, and may be incorporated into one or more walls ofthe pouch or attached thereto. The packaged food product may be capableof being microwaved while sealed in a closed configuration to roast thefood product to a temperature of, e.g., about 120° F. to about 260° F.,150° F. to about 230° F., or 180° F. to 200° F. In some embodiments, theflexible film pouch may be capable of withstanding expansion and/orinternal pressure generated during microwave heating so that it willremain sealed in closed configuration during heating. In otherembodiments, the pouch may be equipped with a relief valve, frangibleseal, vent, or other means to limit interior pressure to a desired levelwithin the pouch during microwave heating, and/or to enable internalpressure to decrease at a desired rate after completion of microwaveheating. The flexible film pouch can include a longitudinal sealextending between end seals, and the one or more vents can include a pinhole or other small opening at a juncture between two seals.

The pouch may be expandable to accommodate increased interior volumeduring heating.

In some embodiments wherein the food product comprises about 0.75 oz. toabout 2 oz. of mixed, shelled nuts, the time period during whichmicrowave heating of the packaged food product takes place may be, forexample, between 20 seconds and 130 seconds, between 60 seconds and 90seconds, or between 70 seconds and 80 seconds, using a 900 to 1200 Wmicrowave oven. In other embodiments, wherein the food product comprisesup to about 6 oz. of mixed, shelled nuts, the time period may be about45 to 360 seconds, or 180 to 360 seconds, again using a 900 W to 1200 Wmicrowave oven. In some embodiments, the packaging may includeinstructions that specify one or more time periods for microwaving atone or more power levels, with one or more longer time periods specifiedfor lower powered microwave ovens, and one or more shorter time periodsspecified for higher powered microwave ovens. In some embodiments, thefood product may comprise a 1 oz. package of mixed nuts comprisingalmonds, peanuts and cashews, and the instructions may specify heatingfor a time period such as 30 seconds or 40 seconds in a 1200 W microwaveoven. The quantities of almonds, peanuts and cashews may beapproximately equal or may vary, for example with each type of nutcomprising about 10% to 50% of the total, by weight. In someembodiments, the microwave heating may comprise warming pre-roastedshelled nuts, finishing roasting of partially roasted shelled nuts, orroasting of raw shelled nuts.

The pouch may be made from a flexible material such as a multilayerflexible film. Examples of layers that may be included in the flexiblematerial include a barrier layer; a printable film layer; an orientedfilm or PET layer; a sealable layer; a protective varnish; and acoefficient of friction modified layer. In some embodiments, theflexible material may include all of the above layers. In otherembodiments, the flexible material may include fewer than all of theselayers. In some embodiments, one or more of the above layers may extendover the entire area of the flexible material. In some embodiments, oneor more of the above layers may be partial or patterned layers,extending over less than the entire area of the flexible material. Insome embodiments, the pouch may include a paper layer that providesstiffness and insulation.

In some embodiments, the pouch may be a generally rectangular structurethat includes a top seal, two side seals and one or more folds, with thefold(s) in the form of a gusset, which can provide the pouch withstand-up stability. In other embodiments, the pouch may comprise agenerally rectangular structure having transverse end seals, alongitudinal seal along a top or bottom wall, and longitudinal foldsconnecting the top and bottom walls. In still other embodiments, thepackage may have a different from configuration. In some embodiments, atear notch, area of weakness, or other means to facilitate opening ofthe pouch by a consumer can be provided in a seal such as a longitudinalseal, transverse seal, side seal, a top seal, or another location.

In some embodiments, headspace of the flexible film pouch can be reducedor minimized via vacuum packaging after shelled nuts are disposedtherein, thereby reducing the overall volume of the package andproviding efficiencies in connection with shipping, handling andstorage. Reduction of headspace can also be advantageous from thestandpoint of increasing the capacity of the package to accommodateexpansion of nitrogen, carbon dioxide, water vapor, and/or other gasesduring heating. In other embodiments, the package may be sealed withouttaking steps to reduce or minimize headspace.

In some embodiments, where the food product comprises shelled nuts, thevolume of shelled nuts may be less than 75% of a total internal packagevolume. In some embodiments, the volume of shelled nuts is between 20%and 40% of the total internal package volume. In some embodiments, thevolume of shelled nuts is about 30% of the total internal packagevolume. In some embodiments, the shelled nuts may be arranged in asingle layer within the package.

The susceptor(s) may comprise discrete components that are attached tothe film by adhesive bonding, heat sealing, or other means, or maycomprise a layer deposited on the film or otherwise provided as anintegral part of the film. In some embodiments, the susceptor(s) mayconsist of one or more metalized layers on the film. Such metalizedlayers may be treated with an acid solution that removes portions of themetalized layer, thereby forming a continuous metalized layer into apatterned susceptor. In some embodiments, the susceptor(s) may compriseone to three discrete susceptors. In some embodiments, a first wall ofthe pouch can have a first susceptor thereon, and a second wall of thepouch can have a second susceptor thereon spaced from the firstsusceptor, with care being taken to avoid contact between thesusceptors. The susceptors can be positioned and configured to heat andbrown portions of the shelled nuts and provide an aroma release withoutexcessive heating or scorching. In some embodiments, the susceptor canbe disposed in a pattern on the flexible film, spaced from packageseals. In some embodiments, the packaged food product can includeflavorings, which may include aroma-enhancing compositions, which may beapplied to the nuts prior to placing them in the pouch, and/or otherwiseplaced in the package. Flavor application may comprise, e.g., soakingshelled or unshelled nuts in a liquid, spraying a liquid onto the nuts,tumbling the nuts in a drum with a particulate flavor treatment such asa powder or granular material, and/or spraying or otherwise introducingliquid and/or particulate flavor treatments into the package after thenuts have been placed therein. Methods of providing flavor treatmentsmay alternatively or additionally further include at least one of:depositing flavoring on an inside surface of the multi-layer flexiblefilm that forms the film tub; spraying flavoring into the film tubeprior to forming the second seal of the flexible film pouch; andspraying flavoring onto the shelled nuts prior to depositing the shellednuts in the flexible film pouch. The method can alternatively oradditionally include depositing flavoring on an inside surface of themulti-layer flexible film prior to forming a film tube, and/or sprayingflavoring into a film tube prior to forming it into a pouch, and/orother steps.

In some embodiments, flavorings may include without limitation one ormore natural natural flavors, savory or sweet seasonings or spices.Examples include without limitation salt, black pepper, cinnamon, honey,sugar, peanut oil, caramel, coconut, and other liquid or dry seasonings.The flavor treatments may include a first coating and a second coating,wherein the first coating functions to improve retention of a secondcoating. The coating can be effective to absorb and/or reflect a portionof the microwave energy to which it is exposed while also beingpermeable to another portion of the microwave energy. To enhance flavor,aroma and/or other organoleptic properties, an aromatic compound can bedisposed on an inside surface of the flexible film pouch prior topackaging the shelled nuts. Alternatively or in addition, a sprayablearomatic compound can be sprayed into the flexible film pouch afterdepositing the shelled nuts therein. In some embodiments, the shellednuts can include one or more of whole nuts, halves, or other pieces withdimensions of about ¼″ to 1″ in length and ⅛″ to ½″ in width. Shellednuts may be pre-roasted at various roast levels and/or steam pasteurizedprior to packaging within the flexible film pouch. The shelled nuts maybe partially roasted, with final roasting being accomplished bymicrowave heating by the consumer. The shelled nuts can have a moisturelevel that decreases by 15%-25% during pre-roasting, while increasingthe composition of volatile compounds associated with a darker roast.The pre-roasted shelled nuts may optionally have undergone at least oneof a dry roast or an oil roast. In some embodiments, the shelled nuts inthe packaged food product comprise roasted or partially roasted peanutsand other nuts having a moisture level of about 1.1% to about 1.4%.Standard moisture levels for the shelled nuts may range from 2.6%-2.9%for almonds, 1.4-1.6% for peanuts, and 1.8%-2.4% for cashews. In someembodiments, savory coated nuts in the packaged food product may have amoisture level of 1.5%-2.6%, including moisture in the coating and nuts.In some embodiments, sweet glazed nuts in the packaged food product mayhave a moisture level of 1.0%-1.6%, including moisture in the glaze andnuts.

In some embodiments, the packaged food product can further include asealed overwrap around the flexible film forming the pouch that isremoved prior to microwaving. The overwrap can be gas flushed prior tosealing.

A method can be provided that includes wrapping a web of multi-layerflexible film into a film tube; providing at least one susceptor insidethe film tube; forming a first end seal to partially form a flexiblefilm pouch; depositing about 0.75 oz. to about 2 oz. shelled nuts in thepartially formed flexible film pouch; gas flushing the partially formedflexible film pouch to reduce oxygen therein; forming a second end sealin the flexible film pouch; wrapping the flexible film pouch in anoverwrap film thereby forming an overwrap pouch; gas flushing theoverwrap pouch to reduce oxygen in the overwrap pouch; and sealing theoverwrap pouch around the flexible film pouch. Gas flushing may comprisereplacing oxygen with nitrogen, carbon dioxide, and/or another gas ormixture of gases so that less than about 2% oxygen is present in thepouch headspace to reduce or minimize oxidation during the product shelflife. In some embodiments, where the gas flushed pouch is made of amaterial that includes an oxygen barrier, the product may have a shelflife of about one year or 365 days, whereas a similar product withoutgas flushing may have a shelf life of only about one month.

A method of using a packaged food product is also provided herein. Insome embodiments, the packaged food product may include about 1 oz. toabout 1.5 oz. of shelled nuts. In some embodiments, the packaged foodproduct may include about 1.0 oz. of shelled nuts. The packaged foodproduct may also include a heat-activated aroma-release composition. Insome embodiments, each of the shelled nuts individually has a mass of 28grams+/−5 grams to 42 grams+/−5 grams. The shelled nuts may be arrangedin a single layer on a susceptor within a sealed flexible package havinga vent opening with a frangible closure, the shelled nuts comprisingabout 1.0% to about 2.0% moisture and having a predetermined aggregatesurface area. The method may include first maintaining the packaged foodproduct at ambient temperature and pressure; thereafter exposing thepackaged food product to microwave energy for a period of about 25seconds to about 100 seconds, or a period of about 30 seconds to 70seconds, or a period of about 35 to 65 seconds, to heat the shelled nutsand reduce their moisture content to between about 0.9% and about 1.3%,and simultaneously vaporizing moisture within the package to expand thepackage and increase its interior pressure, wherein the increase ininterior pressure ΔP does not result in rupture of the package sealsexcept for the frangible closure associated with the vent opening.Preferably, heating the nuts results in a darkening of portions of theaggregate nut surface area. In some embodiments, the darkened portionsare in contact with or in close proximity to the susceptor duringheating. The darkened portions may comprise, e.g., about 10% to about25% of the aggregate nut surface area. The method may further includethereafter removing a portion of the package or otherwise opening thepackage to release a roasted-nut aroma, and in some embodiments, toprovide an open-topped container to provide hand-held access to theheated shelled nuts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a first embodiment of a microwavesusceptor package containing unshelled nuts, showing a pair of end sealsand a fin seal configured to form a top panel and a bottom panel;

FIG. 2 is a plan view of a segment of a susceptor material disposed onone of the panels of the package of FIG. 1;

FIG. 3 is a front perspective view of a second embodiment of abottom-gusseted, standup microwave susceptor package containingunshelled nuts, showing a pair of side seals, a top portion having beenremoved, and showing a food product comprising shelled nuts followingmicrowave heating;

FIG. 4 is a schematic diagram of a process for providing a heated foodproduct, including placing a packaged food product in a microwave oven,heating the packaged food product, then removing a portion of thepackage to serve the food product;

FIG. 5 is a front elevation view of a packaged food product inaccordance with FIG. 3, empty and prior to removal of the top of thepackage, showing a peripheral seal area along the top and sides of thepackage;

FIG. 6 is a plan view of a web of film showing sealing areas and cutlines for use in forming the package of FIG. 5;

FIG. 7 is a plan view of a first alternative web of film showing sealingareas and cut lines for use in forming the package of FIG. 5, similar tothat of FIG. 6 but showing a susceptor added to the interior of whatwill be one of the panels of the package;

FIG. 8 is a plan view of a second alternative web of film showingsealing areas and cut lines for use in forming the package of FIG. 5,similar to that of FIG. 6 but showing susceptors added to the interiorof what will be both panels of the package;

FIG. 9 is a plan view of a third alternative web of film showing sealingareas and cut lines for use in forming the package of FIG. 5, similar tothat of FIG. 6 but showing one or more susceptors added to the interiorof what will be one of the panels of the package;

FIG. 10 is a graph showing comparative magnitudes of selected aromacomponents associated with shelled mixed nuts at room temperature, andafter warming with and without a susceptor;

FIG. 11 is a table showing comparative magnitudes of selected aromacomponents associated with individual varieties of shelled nuts at roomtemperature and after warming with a susceptor; and

FIGS. 12-15 illustrate examples of raw data generated using gaschromatography-mass spectroscopy to measure aroma components.

FIG. 16 provides numerical data that is illustrated graphically in FIG.10.

FIG. 17 is a table showing comparative magnitudes of selected aromacomponents associated with individual varieties of shelled nuts at roomtemperature and after warming with a susceptor.

FIG. 18 is a side elevational sectional view of the packaged foodproduct of FIG. 1.

FIG. 19 is an end sectional view of the packaged food product of FIG. 1.

FIG. 20 is a side view of a packaged food product in accordance withFIG. 3.

FIG. 21 is a front view of the packaged food product in accordance withFIG. 3.

DETAILED DESCRIPTION

Packaged food products suitable for microwave heating are describedherein, including with reference to FIGS. 1-21.

In one embodiment, a packaged food product, shown in FIGS. 1, 18 and 19,has a low profile and is configured to be microwaved on its side, i.e.,in a generally horizontal position such that its length and width aregreater than its height. In this embodiment, the packaged food productincludes a pouch or package 10 that includes an uninterrupted,continuous bottom wall 22, pair of end seals 12, 14 and a top wall 16having a fin seal 18 extending longitudinally thereof. In someembodiments, the package 10 may be made in a high-speed, high volumeautomated form-fill-seal operation in which a web of film is formed intoa tube, with edges brought together to form the longitudinal fin seal,and with the transverse end seals formed at predetermined spacing beforeand after loading of product and gas flushing, and with the packagesbeing separated from one another by cuts through the end seals. Theinterior of the package optionally includes one or more susceptors 20.For example, a grid-like susceptor material, shown in FIG. 2, can beprovided on one or both sides, i.e., on one or both of the top andbottom of the package so as to be positioned above, below, or both aboveand below the food product during heating. In some embodiments, thepackage contains a large number of discrete food items, e.g., a mixtureof shelled nuts, such as almonds, cashews and peanuts. In someembodiments, the food items may be arranged in a single layer orprimarily in a single layer, with all or most of the discrete food itemsbeing in contact with or at least in close proximity to the bottom ofthe package during heating. In these embodiments, most or all of thefood items may also be in contact with, or at least in close proximityto, the top of the package as well, at least initially during microwaveheating. As microwave heating progresses, expansion of the pouch maylift the top surface and an associated susceptor from the food items,which may have a self-regulating effect on the heating operation toreduce or avoid overheating and/or or scorching due to variations inmicrowave energy, heating time or other parameters. Expansion of thepouch may also result in the edges of the bottom wall being raised fromthe floor of the microwave oven, and may change the arrangement of someor all of the food items from a single-layer configuration to amultiple-layer configuration in which some of the food items to overlieothers, which may also have a self-regulating effect on the heatingoperation to help reduce or avoid overheating and/or scorching.

In a second embodiment, shown in FIGS. 3, 5, 20 and 21, a packaged foodproduct includes a package or pouch 24 that is configured to stand upduring and/or following microwave heating. The pouch 24 can include apair of side seals 26, a top seal 28 and a bottom 30, shownschematically in FIG. 5. A top portion of the pouch, which encompassesthe top seal, is configured for removal. The pouch is shown afterremoval of the top portion in FIG. 3.

As shown in the schematic diagram of FIG. 4, in some embodiments, apackaged food product such as either of the above-described packagedfood products can be inserted into a microwave oven, heated usingmicrowave energy, then removed from the microwave oven, after which aportion of the package may be removed, separated or otherwise opened toprovide access to the contents.

In some embodiments including but not limited to those described above,the pouch can be formed from a web of film 36, various examples of whichare shown in FIGS. 6-9. The web of film can be folded so that regions 38and 40 form the front and rear of the package, with seals 42 and 44being formed on the sides and top. In some embodiments, the bottom cancomprise a single fold along line 46. Alternatively, a gusseted bottommay be provided. A web of film can be configured without a susceptor, asshown in FIG. 6, or with one or more susceptors 48 added prior tosingulating the package from the web of film, as shown in FIGS. 7-9. Forexample, a single susceptor 48 can be attached to the web of film in anarea that will be an interior surface of one of the front or rear wallsof the package, as shown in FIG. 7. Alternatively, a pair of susceptorsurfaces can be provided on the web of film in areas that will beinterior surfaces of the front and rear walls of the package, as shownin FIG. 8. In another alternative, multiple types of susceptors may beincorporated on a single panel, as shown in FIG. 9, or on other panels,to provide increased localized conductive heat transfer in a particularregion of a susceptor. Optionally, the susceptor surfaces can bepositioned closer to the bottom of the package than the top such thatthey will be adjacent the food product near the bottom of the packageduring microwave heating.

Aroma is created during microwave heating due to a combination of theproduct and the packaging, and is released upon opening of the packagefollowing microwave heating, and/or through a vent during heating. Thearoma from the product can be generated not only by the nuts but also byadditional ingredients. Liquid coatings, dry seasonings and/or otheringredients may include heat stable components that are added to nutsprior to packaging and provide aroma upon opening of the packagefollowing microwave heating. In addition to a dry seasoning or coating,a liquid seasoning can optionally be added to the nuts either before orafter the application of a dry seasoning to increase the amount ofvolatile components released during microwave heating. One option is toalso or instead add aroma-contributing compounds to the packagingmaterial, such as by spraying the compounds on one or more interiorsurfaces of the package, such as in the headspace, after depositing thenuts and prior to sealing.

The blend of sizes of particulates in the coating as well as thephysical characteristics, such as high melting temperatures, can help tomoderate heating of nuts by absorbing or reflecting microwave energyand/or by shielding shelled nuts from microwave energy. This canadvantageously reduce the amount of microwave energy that is absorbed bythe interior and surface of the nut, thereby leading to increasedhomogeneity of the heating among the nuts and allowing the product toachieve an overall higher temperature without overheating individualareas of the nuts. Certain coatings may tend to increase susceptortemperature by reflecting microwave energy that would otherwise beabsorbed by shelled nuts or other edible substrates to which thecoatings are applied. This can help to provide desirable organolepticproperties such as crunchiness of the coatings and underlying shellednuts, while avoiding undesirable organoleptic properties such asundesirable softness of the shelled nuts. Other coatings may tend todecrease susceptor temperature by absorbing microwave energy.

In some embodiments, low-moisture sugar-based coatings or otherlow-moisture coatings may be preferable to higher moisture coatingsincluding those based on corn syrup from the standpoint that coatingsbased on corn syrup may tend to flow more easily when heated totemperatures of, e.g., 215° or 230° F., with portions of the coatingsundesirably liquefying and running off the underlying food items whenheated rather than remaining adhered thereto. Specific flavor notes thatmay be provided by the food products and/or coatings include but are notlimited to sweet, savory, and salty flavor notes, and combinationsthereof. Specific flavors for food products and/or coatings may includebut are not limited to, e.g., salted caramel, cinnamon almond, and sweetroasted cashew flavors. Examples of specific product formulas that maybe used in some embodiments are provided below.

Seasoned Cashew Ingredient Range (%) Cashew  92-98  Peanut oil 0.5-2.5Powdered seasoning   2-6  

Sea Salt Nut Blend Ingredient Range (%) Almond 30-50 Cashew 24-44 Peanut16-36

Sea Salt Almond Ingredient Range (%) Almond  94-99 Peanut oil 0.5-3 Salt 0.5-3 

Coconut Cashew Ingredient Range (%) Cashews   60-85 Sugar   20-40Coconut    2-5  Corn syrup  2.5-5  Butter   1-2  Salt  0.5-2  Flavor0.05-.2 

Salted Caramel Peanut Ingredient Range (%) Peanuts   60-85   Sugar  20-40   Salt  0.5-2    Caramel seasoning 0.25-0.75

Cinnamon Almond Ingredient Range (%) Almonds  55-85 Sugar  20-40 Salt0.5-2  Cinnamon 0.5-3 

In some embodiments, thicker coatings can contribute to increasedcooking homogeneity. In some embodiments, coatings may have a thicknessof about 1 to 3 mm, and in some cases may have an average thickness ofabout 1 mm.

The packaging can contribute to the aroma by providing suitable barrierlayers and a headspace for the aroma to accumulate. For example, thepouch can be a multilayered structure that contains a barrier material,such as EVOH (ethylene vinyl alcohol), AlO_(x) (aluminum oxide) orSiO_(x) (silicon oxide), that limits the migration of aroma componentsthrough the package during both shelf life and microwave heating. Thebarrier material can be provided either as part of the pouch or in outerpackaging that is removed prior to microwave heating. The package ispreferably sealed during microwave heating so that volatile compoundsthat provide the aroma do not leave the package until opened. It can bedesirable to optimize the headspace in the package in order to enable amore concentrated aroma while also ensuring space for the aroma todevelop.

The temperatures achieved during microwave heating contribute to thearoma as well as to heating of the nuts. One way to use temperaturesduring microwave heating to contribute to aroma is to design the coatingand dry seasoning ingredients to maximize their dielectric propertieswhen applied to a nut to enable more quick and homogenous heating.Another way to use temperatures during microwave heating to contributeto aroma is to add one or more susceptors within the package to enablelocalized, conductive heating with the package. The susceptor can bedisposed and/or more concentrated in an area of the package most likelyto contain the nuts, e.g., the bottom portion in a stand-up package.

In one example, the package contains about 1 to 1.5 ounces of eithercashews, almonds or shelled peanuts, or combinations thereof. Thepackage can include a susceptor to optimize heating of the nuts duringmicrowave heating. The package can optionally be gas-flushed. Thepackage can be heated in a microwave for between 30 and 60 seconds, forexample.

In some embodiments, strategically-configured susceptors are provided ina configuration that enables localized heating of certain portions ofthe mixed nuts to a higher temperature that enhances the aromacharacteristics of the product without unacceptably overheating theshelled nuts, optionally in combination with one or more coatings thatmay provide quantitative and qualitative aroma enhancements. Coatingsmay also enable positive or negative variation of the shelled nuts'thermal response to microwave heating.

The aroma data in FIGS. 10 and 11 were compiled by exposing shelled nutsto microwave energy with and without susceptors, and using gaschromatography-mass spectroscopy to quantify increases in particulararoma components as a result of use of a particular susceptorconfiguration.

FIGS. 11 and 17 show data from shelled nuts, some including flavortreatments, measured at room temperature and after microwave heatingwith a susceptor in a package as described above. FIG. 11 shows, forexample, that microwave warming of almonds resulted in about a two-foldincrease in an ethyl-pyrazine aroma component, which is associated witha “roasted” or “nutty” aroma, an eighteen-fold increase in a diacetylaroma component, which is associated with a “buttery” aroma, and arelatively small increase in furfural (caramel) aroma. FIG. 17 providesadditional data for the same microwave warming, showing that it resultedin a two-fold increase of methyl pyrazine (roasted) aroma.

In some embodiments, microwave heating of a 1 oz. package of cinnamonalmonds, i.e. almonds with a cinnamon coating as described above,according to instructions provided on packaging as described above, maydesirably result in a significant increase of aroma components in theheadspace, e.g., an increase in furfural aroma by a factor of 100 to200, or more specifically a factor of 120 to 170, or a factor of about144; an increase in ethyl pyrazine aroma by a factor of 10 to 50, ormore specifically, a factor of about 31; an increase in methyl pyrazineby a factor of 15 to 100, or by a factor of about 50 to 60, or by afactor of about 56; and an increase in diacetyl aroma by a factor of 5to 200, a factor of 40 to 60, or a factor of about 50. (See FIGS. 11 and17.)

In some embodiments, microwave heating of a 1 oz. package of cashewsaccording to instructions provided on the packaging as described abovemay desirably result in a significant increase of aroma components inthe headspace, e.g., an increase in furfural aroma by a factor of 100 to250, or more specifically a factor of 150 to 200, or a factor of about167; an increase in ethyl pyrazine aroma by a factor of 50 to 200, ormore specifically, a factor of 100 to 150, or a factor of about 125; anincrease in methyl pyrazine by a factor of 25 to 80, or by a factor ofabout 50 to 60, or by a factor of about 56; and an increase in diacetylaroma by a factor of 200 to 400, a factor of 250 to 350, or a factor ofabout 289. (See FIGS. 11 and 17.)

FIGS. 10 and 16 illustrates differences in aroma values that result fromusing a particular susceptor package or a non-susceptor package inmicrowave heating of mixed nuts.

The data in FIGS. 10, 11, 16 and 17 correspond to desirable aromaproperties of packaged food products described herein, and such packagedfood products in some embodiments may enable consumers to achieveincreases in various key aroma components similar to those describedherein, e.g., within 10%, 20%, 30%, 40% or 50% of the values in FIGS.10, 11, 16 and 17, while also providing other desirable organolepticproperties, without scorching or generation of undesirable aromas.

Examples of raw data generated using gas chromatography-massspectroscopy to measure selected individual aroma components areprovided in FIGS. 12-15. The areas under the plots shown in FIGS. 12-15is the “Peak Area” represented by the y-axis in FIG. 10.

Data shown in FIGS. 12-15 was gathered by collecting gases from withinpouches containing a mixture of shelled nuts, specifically almonds,cashews and peanuts, on thermal desorption tubes before and aftermicrowaving with and without susceptors. Sampling was performed usingadhesive septas (Illinois Instrument PPL-193456). Headspace samples werecollected for 2 min using a vacuum pump pulling 50 mL/min (FIG. 1). Gasdisplaced was replaced using food grade nitrogen.

The following additional equipment was used in sampling and analysis:

Agilent Technologies 5975 Mass Spectrometer Agilent Technologies 6890NNetwork GC System Gerstel TDS3 Thermal Desorption System Gerstel TDSAThermodesorption Autosampler Envirochem Multiple Tube Conditioner

Thermal Desorption tubes; 3.8 mm Tenax-TA, 2.0 mm Carboxen 1003

Additional information on equipment and parameters used is set forthbelow:

GC-MS Parameters:

Oven

Equilibration time: 1.00 minMaximum temp: 250 CInitial temp: 35 C (On)Initial time: 4.00 min

Ramps:

# Rate Final Temperature Final Time 1 3.00  82 0.00 2 6.00 210 10.00 3 0(off)Post temp: 240 CPost time: 5.00 minRun time: 51.00 min

Column: Agilent VF-WAX P/N CP9295

Back Inlet (CIS4)

Mode: Solvent Vent

Initial temp: 0 C (Off)

Pressure: 8.8 psi (On)

Vent time: 0.00 minVent flow: 50.0 mL/min

Vent Pressure: 8.8 psi

Purge flow: 50.0 mL/minPurge time: 2.00 minTotal flow: 54.0 mL/minGas saver: OffGas type: Helium

Thermal AUX 2

Initial temp: 240 C (On)

Gerstel Maestro

System Settings

Maestro Runtime: 55.99 min GC Cool Down Time: 8.00 min Cryo Timeout:25.00 min

1-18. (canceled)
 19. A packaged food product, comprising: a flexiblefilm forming a pouch having an interior cavity formed by a first endseal and a second end seal with a longitudinal fin seal extendingtherebetween, the flexible film pouch being substantially hermeticallysealed in a closed configuration; at least one susceptor disposed on amajority of an interior surface of the flexible film pouch withoutcontacting the first end seal, the second end seal, or the fin seal;about 0.75 oz. to about 2.00 oz. pasteurized or at least partiallyroasted shelled nuts disposed within the interior cavity of the flexiblefilm pouch, the shelled nuts having been pasteurized or at leastpartially roasted prior to being disposed within the flexible filmpouch; a coating on the shelled nuts being one of: a sweet glaze on theshelled nuts, wherein the sweet glaze and the shelled nuts have acombined moisture level within the range of 1.0% to 1.6%; or a savorycoating on the shelled nuts, wherein the savory coating and the shellednuts have a combined moisture level within the range of 1.5% to 2.6%;wherein the packaged food product is configured and arranged to beheated in a microwave oven in the closed configuration to roast theshelled nuts to a temperature of about 120° F. to about 260° F.; andwherein the coating and the at least one susceptor are configured andarranged to moderate heating of the shelled nuts by absorbing and/orreflecting microwave energy thereby reducing an amount of microwaveenergy absorbed by the shelled nuts and increasing homogeneity ofheating the shelled nuts.
 20. The packaged food product of claim 19,wherein the flexible film is a multilayered film including a barriermaterial configured and arranged to limit migration of aroma componentsthrough the flexible film during storage and during microwave heating.21. The packaged food product of claim 20, wherein the barrier materialis selected from the group consisting of EVOH, AlO_(x), and SiO_(x). 22.The packaged food product of claim 19, wherein the first end seal, thesecond end seal, and the fin seal are configured and arranged to remainsealed and not rupture during microwave heating.
 23. The packaged foodproduct of claim 19, wherein a volume of shelled nuts is less than 75%of a total internal package volume, and wherein a volume of oxygen isless than 2% within the interior cavity of the flexible film pouch,further comprising a headspace within the interior cavity between theshelled nuts and the flexible film configured and arranged to allowaroma to develop during microwave heating.
 24. The packaged food productof claim 19, wherein the coating is 1 mm to 3 mm thick on each of theshelled nuts.
 25. The packaged food product of claim 19, wherein theflexible film includes a bottom wall portion and a top wall portioninterconnected by the first end seal and the second end seal, the finseal extending between the first end seal and the second end seal on thetop wall portion, and wherein the at least one susceptor includes afirst discrete susceptor on the bottom wall portion and a seconddiscrete susceptor on the top wall portion.
 26. The packaged foodproduct of claim 19, further comprising nut flavorings comprising atleast one of salt, black pepper, cinnamon, honey, sugar, peanut oil,caramel, and coconut.
 27. The packaged food product of claim 19, whereinthe sweet glaze or the savory coating is adapted to absorb and/orreflect microwave energy during exposure of the packaged food productthereto and be permeable to a portion of the microwave energy.
 28. Thepackaged food product of claim 19, wherein the shelled nuts arepasteurized with a moisture level decreased by 15% to 25% duringpasteurization.
 29. The packaged food product of claim 19, wherein theshelled nuts are at least partially roasted having a moisture levelbetween about 1.1% to about 1.4% due to the at least partial roasting.30. The packaged food product of claim 19, wherein the shelled nuts arecaramel peanuts having about a 64-fold increase in ethyl-pyrazine aromacompounds, about a 53-fold increase in furfural aroma compounds, andabout a 21-fold increase in diacetyl aroma compounds after microwaveheating.
 31. The packaged food product of claim 19, wherein the shellednuts are cinnamon almonds having about a 31-fold increase inethyl-pyrazine aroma compounds, about a 144-fold increase in furfuralaroma compounds, and about a 50-fold increase in diacetyl aromacompounds after microwave heating.
 32. The packaged food product ofclaim 19, wherein the shelled nuts are coconut cashews having about a54-fold increase in ethyl-pyrazine aroma compounds, about a 155-foldincrease in furfural aroma compounds, and about an 93-fold increase indiacetyl aroma compounds after microwave heating.
 33. The packaged foodproduct of claim 19, wherein the food product includes 20% to 40% sugar.34. A packaged food product, comprising: a flexible film forming a pouchhaving an interior cavity formed by a bottom wall portion and a top wallportion, the bottom wall portion and the top wall portion beinginterconnected by a first end seal and a second end seal, a longitudinalfin seal extends between the first end seal and the second end seal onthe top wall portion, the flexible film pouch including a barrier theflexible film pouch being substantially hermetically sealed in a closedconfiguration; at least one susceptor disposed on a majority of aninterior surface of the flexible film pouch on the bottom wall portionand the top wall portion without contacting the first end seal, thesecond end seal, or the fin seal; about 0.75 oz. to about 2.00 oz.pasteurized or at least partially roasted shelled nuts disposed withinthe interior cavity of the flexible film pouch, the shelled nuts havingbeen pasteurized or at least partially roasted prior to being disposedwithin the flexible film pouch; a coating on the shelled nuts being oneof: a sweet glaze on the shelled nuts, wherein the sweet glaze and theshelled nuts have a combined moisture level within the range of 1.0% to1.6%; or a savory coating on the shelled nuts, wherein the savorycoating and the shelled nuts have a combined moisture level within therange of 1.5% to 2.6%; a headspace between the shelled nuts and theflexible film; wherein the packaged food product is configured andarranged to be heated in a microwave oven in the closed configuration toroast the shelled nuts to a temperature of about 120° F. to about 260°F., and wherein the first end seal, the second end seal, and the finseal are configured and arranged to remain sealed and not rupture duringmicrowave heating; and wherein the coating and the at least onesusceptor are configured and arranged to moderate heating of the shellednuts by absorbing and/or reflecting microwave energy thereby reducing anamount of microwave energy absorbed by the shelled nuts and increasinghomogeneity of heating the shelled nuts.
 35. The packaged food productof claim 34, wherein the flexible film is a multilayered film includinga barrier material configured and arranged to limit migration of aromacomponents through the flexible film during storage and during microwaveheating.
 36. The packaged food product of claim 34, wherein a volume ofshelled nuts is less than 75% of a total internal package volume,wherein a volume of oxygen is less than 2% within the interior cavity ofthe flexible film pouch, and wherein the shelled nuts and the headspaceare configured and arranged to allow aroma to develop during microwaveheating.
 37. The packaged food product of claim 34, wherein the sweetglaze or the savory coating is adapted to absorb and/or reflectmicrowave energy and be permeable to a portion of the microwave energyduring exposure of the packaged food product thereto.
 38. The packagedfood product of claim 34, wherein the shelled nuts are pasteurized witha moisture level decreased by 15% to 25% during pasteurization.
 39. Thepackaged food product of claim 34, wherein the shelled nuts are at leastpartially roasted having a moisture level between about 1.1% to about1.4% due to the at least partial roasting.
 40. The packaged food productof claim 34, wherein the food product includes 20% to 40% sugar.